Secondary Operations in the Roll Forming Line

Punching, Perforating, Notching, and Mitering :

Secondary Operations in the Roll Forming Line: In the punching process, a part of the material remove by shearing from the body of the material. The removed part is scrap. These processes shall not be mixed up with blanking(stamping) in the blanked out slug is the product, and the remainder of the strip is scrap. Blanking is not a process used in roll-forming lines. Punching and notching and mitering, and other press operations can complete in the roll forming line. In the punching process, a part of the material remove by shearing from the body of the material. The removed part is scrap. These processes shall not mix up with blanking(stamping) in the blanked out slug is the product, and the remainder of the strip is scrap. Blanking is not a process used in roll-forming lines. Punching, notching, mitering, and other press operations can complete in roll forming line.






Punching incorrectly calls piercing. Piercing is achieved with special punches, which leave a hole in the material and flange it without creating a slug.

a Perforating is punching a large number of small holes in a symmetrical pattern.
Perforating requires special equipment and tooling.
In some cases, a perforated pattern can be punched in-line at high speed. Having this process included in the line could save considerably on the cost of buying and stocking pre-perforated coils.

Punching process

Punching process

as you know, Notching is a process where part of the strip edge is cut out. Sometimes, punched holes cut through at a later stage appear as notches in the finished products.
in fact, Mitering is a punching or notching operation, which prepares the ends of the formed profile to fit for bending assembly. This process is applied to make frames for pictures, windows, doors, and other products.

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Rollers production rollers manufacturing

What is Rolling Process

Machining process roller:The rolling process is the shaping of metals into semi-finished or finished forms by passing between rollers rotating in opposite directions. Rolling is the most important metal forming process because of its lower cost. The purpose of rolling is to decrease the thickness of the metal.




Machining process roller: The deformation takes place when a pressing force is applied by a set of rolls on an ingot or any other product like billets, blooms, sheets, slabs, plates, strips, etc. This deformation decreases the cross-section area of the metal and converts it into the required shape. The main purpose of rolling is to decrease the thickness of the metal.



CNC Machining

In fact, CNC Machining is often a part of the early stages and finishing processes in roller manufacturing.
Computer Numerical Control (CNC) machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery.  The process can be used to control a range of complex machinery, from grinders and lathes to mills and CNC routers. in fact, As the tools rotate and move across the surface of the workpiece, they slowly remove excess material to achieve the desired shape and size.

shaft manufacturing process

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Cable ladder vs cable tray

Cable ladder

ladder tray, cable runway, or cable ladder has a range of direct lengths and different shaped fittings design to comfort changing cabling directions or levels easily, without the need to modify any components.
cable ladders are considered to be the strongest products that are available to support cables.
the cable ladders can offer high load capabilities over long spans.
so they install on sites where they need to distribute high volumes of cables.
rungs are perforated, which makes it easy to fasten cable ties or cable cleats directly onto the ladder.
It is of the stronger build
Configuration is easy.
Air circulation is free hence derating of cable current carrying capacity is not required.
Fewer accessories are required.
Can carry more load
Supports heavy cables
Cables are easily accessible

Cable ladder machine

What is the difference between cable ladders and cable trays?

cable tray roll forming machine

Cable Tray

Cable tray use for easier to lay new cables onto a tray system as the needs of a project change over time.
the Cable trays although perforate, but airflow is not as free as in the cable ladders. but Cable trays are mechanically safer than in the cable ladder.
a Cable Tray has a single sheet of metal. Suitable for light electrical and instrumentation cables.
they are the most aesthetically pleasing option.
Covers can be added to protect cabling against UV.

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Pre-cut vs post-cut roll forming machine

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How to choose your roll forming machine?


Roll forming is a continuous bending method in which a long tape of sheet steel is passed via rolls mounted on successive stands, each set executing only an incremental part of the bend, till the preferred cross-part profile is obtained. Roll forming is perfect for generating continuous-profile components with long lengths and in big quantities.

Pre-cut vs post-cut roll forming machine: There are two different types of roll forming machines, a Pre-Cut roll forming machine, and Post Cut roll forming machine. There are advantages as well as disadvantages to both.

Advantages and disadvantages Pre-Cut roll forming machine 

Pre-cut advantages:

  • remove costly cut-off dies and their maintenance
  • Simple low-keeping pre-cut shear
  • Ability to hand-feed strips or sheets for low-volume production
  • In roofing and wall panel products, pre-cut avoids cut-off distortion

Pre-cut disadvantages:

  • need more forming stations making the roll former and tooling more expensive
  • need more floor space
  • Difficult multi-bend parts
  • Pre-cut may require intermediate guides, especially when running short pieces.

Advantages and disadvantages post-Cut roll forming machine 


  • The production rate is higher with post-cut.
  • Better part control in terms of quality.
  • Better results for high-strength steels.
  • Lengths as short as 2 into 3 can produce.
  • Ability to provide punching/notching during the cut-off operation.


  • Expensive cut-off press and die.
  • Maintenance costs, especially for the cut-off die.
  • Distortion on product end.

Before investing in roll forming equipment, shops should select a manufacturer that can provide them with leading-edge designs and cost-effective solutions to satisfy any of their metal roll forming project needs. in fact, LOTOSFORMING is a leading roll forming industry in China for design roller and roll forming machines for other cooperators. We may build up the future altogether. Two basic types of roll forming systems are utilized: a pre-cut line and a post-cut line. certainly, a pre-cut line snips the incoming material to a specific length prior to roll forming. also, During post-cut line operation, the roll-formed panel runs continuously after roll forming. you want to know Pre-cut vs post-cut roll forming machine please study this article.

Howdy, lotos forming

pre-cut-roll-forming-machine low

post cut roll forming machine

Roll Forming Machine Cutting Method:

Different cutting for the different profile on the Rollforming machine including:

1. Cold cutting saw adjustable cutting angle

2. Cold gear saw for some close type with a low thickness profile

3. This hydraulic waste cutting

4. Laser or plasma cutting is used for welding tube

5. Hydraulic bending and cutting mold

6. 45-degree cutting left and right side it mostly uses for door and windows frame

7. servo tracking hydraulic cutting

in fact, We help you to choose a suitable cutting method according to the roll forming processing according to production requirements.

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All in one roll forming machine vs Cassette Type roll forming machine


All in one roll forming machine

All in one roll forming machine vs Cassette Type roll forming machine: today we are going to make some video to explain to you once the customer said I need that the roller roll forming machine or I need the cassette roll forming machine. sometimes a customer wants to combine their different profile into one single machine. there is some possible way, of course, and there but there is some choice one choice is a cassette and another choice is changing the roller.

but sometimes we will agree to change the roller for the customers for the sometimes we don’t. it depends on their profile what kind of profile the customer wanna make. the other one also depends on the rollers if we complicate one or it’s an easy one to change.
Different roll forming machines can use to make different roll forming products, such as double roll forming machines and all-in-one roll forming machines, etc. However, cassette type roll forming machines always come to people’s minds in some times.

 Roll forming machines

suppose there is one new machine and we want to insulate it that the rollers. here we are some measure it’s not a high technology way but it’s, of course, there are some traditional and useful the way. we make some liner to make sure the roller central will be in the same line.  in the first step, workers will put their rollers together with the shaft.
and after installation the rollers the shaft end the bearing broke and we had the problem also we have the up layer(up roller) and the down layer(down roller). The second step is how we adjust the shape to qualify.
An all-in-one roll forming machine usually consists of one decoiler, one roll former,  one cutter, one control box, one oil pump, and one set of run-out tables, so it would save working space.

How to adjust the rollers of the roll forming machine


 Cassette Type roll forming machine

All in one roll forming machine vs Cassette Type roll forming machine: The Cassette Type roll forming machine has several sets of individual cassettes tools, consisting of different rolling tools, shafts and operation stand. cassette type roll forming machine design to produce a variety of cold-formed profile by quickly changing different cassettes and sharing the same machine base.
cassette type roll forming machine is popular because they can assemble different cassettes on the main machine base to roll form different metal products.

Variations type roll forming stand

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Adjusting the gap between rollers

How to adjust the rollers of the roll forming machine

ADJUSTING THE GAP BETWEEN ROLLERS: hello, today we’re coming to installation again and setup roll forming machine. it’s a good moment to share with you some special knowledge about setup. we are checking each roller by roller in the middle I’m trying to find out which roller is not in the proper place to adjust it and finalize the system put the mirror down part up part. in our videos, you can how we check in the mirror you see the mirror side you can see the profile inside between the roller and how it going inside like a left and right.



for ADJUSTING THE GAP BETWEEN ROLLERS you can see the down part of the profile and the gap between profile and down roll up you know the gap, left gap, the size maybe here more easily for you to check, you can see from here you pay attention in the mirror so with one mirror and one line time experience and roll forming adjusting you can adjust the step, here see the left and right the gap should be same I’m showing your engineering and as you find out one thing is not in the proper position by your experience by your material thickness materials you can figure out the adjusting going left or going right.

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How to adjust the roller gap

roller-gap how to change roller space? Roll Forming Machine is a flexible and continuous process, where both the normal rules and the exceptions utilized. It has been proven several times that the roll forming machine accomplishes roll forming tasks that even seemingly impossible. Between the rollers are spacers, which will reduce the cost of the mill. And easy to adjust to produce a different desired profile with split spacers. in this post you can learn all thing about: how to install rollers for roll forming machines? • Roll Forming Machine Rollers • how to lose shaft and move space sleeve in roll forming machine • How to adjust the rollers of the roll forming machine • How to Change Spacer Multi-Profile of the roll forming machine • Spacer change for multi-profile roll forming machine • Change size by change spacer for roll forming machine • How to Change Roller Spacers of Roll Forming Machine for Different Profile • adjusting the gap between rollers roll forming machine • How to adjust the roller mold width
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Roll Forming Machine Operator

Roll forming machine operator 

Roll forming machine operator Set up roll forming systems, which include turnstiles, coil carts, decoilers,

 strip welders, recoilers, roll forming parts, punch presses, welding systems, various measuring devices, 

stock straighteners, various coil feed devices, scrap conveyors, part conveyors, automatic material handling, etc.

the operator Perform die repair such as changing roll form sections, punches, buttons, Sharpen punches and make

other repairs as necessary.Forming Roll Operator Set dies and change rolls to produce quality products.

Metal Roll Forming Machine Operator Jobs

 The roll forming Machine Operator will be responsible for operating the equipment.

1.      Feed materials into inline forming machines and perform roll changes as necessary. Observe rollforming machine operation to detect workpiece defects or roll forming machine malfunction.

2.       Set up all work centers within the department in accordance with established procedures and make necessary adjustments to achieve a part that meets all specifications.

3.       Set up duties include but are not limited to; changing molds and dies out of machines, properly securing and connecting utilities to tooling, and installing the proper program into the machine.

4.       Feed materials into inline forming machines and perform roll changes as necessary.

5.       Remove scrap materials from the machine and dispose of per procedures.

6.       Observe machine operation to detect workpiece defects or machine malfunction and report any findings to the Supervisor.

7.       Monitor and measure specific characteristics of the product using measuring equipment.

8.       Inspect quality of finished product and report any quality issues to Setup/Lead Person or Shift Supervisor.

 Roll forming machine Jobs

9.       Input accurate daily production information in the computer shop floor data collection system.

10.   Assist roll forming operators with job functions such as relieving machinery for scheduled breaks, moving product and scrap to and from work stations, and assisting material handler with moving raw materials to and from work stations.

11.   Properly complete all necessary paperwork and forms needed for setup or production.

12.   Recommend measures to improve production methods, equipment performance, and quality of the product.

13.   Perform all work procedures according to established Quality Management & Environmental Management Systems.

14.   Perform job responsibilities and tasks in compliance with Company policies, procedures and safety, and environmental regulations.

Roll Forming Machine Operator

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Decoiler Machine

Decoiler Machine


Decoiler meaning:


A material handling machine located at the beginning of a production line. decoiler used to hold and safely pay off or uncoil the steel strip. Coiler controls the speed and direction of the strip of metal and is sent to the line for processing, such as slitting or tube mill entry also roll forming entry. Decoiling is the action of unwinding a parent coil, making it flat and cutting it into sheets.


Manual Decoiler Machine


Decoiler machine design

actually, there is a sensor between decoiler and roll forming machine. If the coil is tight, the sensor will let the uncoiler go forward. If the coil is loose, the sensor will let the uncoiler stop. in fact, LOTOS specializes in providing custom-built Manual Decoiler to our customers. De-Coiler offered by us finds application as an accessory machine that is used as support for expanded metal mesh machine.

Decoiling Machine

decoiler or uncoiler use in all roll forming machine such as:

Automatic Decoiler Machine


Hydraulic Decoiler Machine 

A manual decoiler is cheaper, while a semi-auto decoiler or an auto decoiler may cost Multiply. A manual decoiler consists of welded steel and two bearings; a semi-auto decoiler requires a motor with a reducer, and an auto decoiler has a motor, hydraulic system, frequency inver, and control unit. 

We produce all kind of decoiler types such as Automatic Sheet Uncoiler Machine, Automatic motorized Uncoiler Machine, Automatic Decoiling Machine, Automatic Uncoiler, Automatic Uncoiler Machine:

Double Head Mechanical Decoilers

Horizontal Mechanical Uncoilers

Mechanical Uncoilers

Motorized Mechanical Decoilers

Hydraulic Decoiler Machine


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Roll Forming Operation Manual


How to adjust a roll former ??

LOTOSFORMING guides and explains many of the common issues encountered in the roll forming process and roll forming operation manual, all factors that contribute to possible problems such as material, design, and manufacture.

roll forming operation manual is a process that developed by gradually bending the metal through a series of roll stands, or passes. Each stand must produce the appropriate amount of deformation for which it was designed. when roll-forming problems occur. it is important to examine each stage of the process and not merely the stand at which the problem initially appears. The goal of a roll forming operation achieves when there is uniform metal deformation throughout the line. Roll forming operation manual design to be reasonable during the operation. If run “popping” throughout the operation, the operation needs to be investigated.

Two basic types of roll forming systems utilize a pre-cut line and a post-cut line. A pre-cut line snips the incoming material to a specific length prior to roll forming operation manual. During post cut line operation, the roll-formed panel runs continuously and shear to the required length after roll forming.


roll former



Roll forming operation :


One of the main parameters that define the success of a roll forming operation is the character of the material. for design the optimal process, the designer should provide material information to use prior to the tooling designing such as material mechanical property ranges, gauge tolerances and shape tolerances, different metallic coatings.



Mill alignment is critical. forming rolls and their components must align with each other both horizontally and vertically. The rolls must align both side-to-side and pass-to-pass. Forming material with the gauge either lighter or heavier than that for which the tooling is designed can result in problems. Using material thinner than the designed gauge can lead to finish radii greater than the intended design. This is usually offset by over-tightening the rolls, which causes a decline in tool life.

 Processing heavier gauge material than intended can also lead to larger radii than designed. When running thicker material, the tooling will make contact on the side of the tool radii leaving no center contact with the tooling. Since the material is not in proper contact with the tooling, gap differences from side to side become more critical. Small side-to-side roll gap differences can result in a twist, bow or sweep problems.

Roll forming components


setup by the roll tooling manufacturer, feeler, or wire gauges is most often used to set the gaps on roll-forming stands. This should ideally be done each time the metal being utilized changes significantly in gauge. Operators must be sure to periodically check for tooling wear or machine wear.

Each stand consists of top and bottom rolls designed to provide the necessary part dimensions. position of the top roll can be adjusted via screws to change the gap between rolls, thereby changing the forming pressure applied to the metal at each stand. The final roll gap adjustment on each stand should always be down to compensate for the gear and bearing tolerances inherent to each stand.



Cutoff dies or shears are available in many types and variations. The most common types utilized for roll forming machines are the “slugless crop die” and the “flying shear”, or “cutoff die”.cutoff operation accurately cuts the part to the desired length in a manner that is essential to the continuous operation of the line. Slugless crop dies generally have a short stroke length, possess contoured blades, and rapidly cut-off the finished part. Since the cut-off action is extremely fast, and accurate cut can normally be performed without interruption to the continuous operation of the line. Proper set-up in this type of operation is critical.


Roll forming machine design

Line speeds, die speeds, and die clearances must closely establish and monitor to prevent blade drag. This condition can result in panel buckling. Removal of the buckled panel from the line is time-consuming and may result in damage to the cutoff die, or in extreme cases, to the roll tooling. Even if the part does not buckle to the point that it jams the line, improperly timed cutting can cause problems upstream in the roll former.

Momentary interruptions in the later roll-forming stand, while the initial stands are still driving the material, can result in a wide variety of problems and/or imperfections. Minor buckling in the intermediate stands can result in oil canning type imperfections as well as other twist or dimensional issues in the finished panel. If the line is set-up with extremely loose tooling clearances. the effect of momentary line interruption from the cutoff operation may be seen all the way to the uncoiler. In this instance, the alignment of the entire line becomes integral to the cut-off operation. For example, if the uncoiler is out of alignment, the momentary line interruption could pull the material in a skewed manner from the uncoiler and potentially cause oil canning, twist or sweep problems.

Roll forming stands

A flying shear, or cut-off die, may require an increase in the line speed or panel height configuration. This allows the shear or die to attain the speed of the line prior to the cutoff operation. The timing of the shear is critical in this operation. Momentary interruptions in the latter roll-forming stands, as described above, will generally be larger in magnitude and more serious in nature as the speed of the cut-off operation increases. blade or die should always cut to an approved part. Improperly design/machine tools must avoid because they result in tight clearances, induce blade drag, tool drag, or lose clearances, which result in burrs on the finished panel.


roll forming machine price

roll forming machine price


Roll forming machine configuration :

With a working knowledge of the roll forming machine configuration and the roll former setup procedures, the root cause of many problems can determine at the plant level. Generally, the most important factor to keep in mind is that roll-forming issues must approach from a systematic point of view. That is, everything must consider from the incoming material properties, lubrication, roll former setup, uncoiler, and cut-off methods to the inspection details of the finished product. All or any of these factors can impact the acceptance of the finished part.


 adjusting the roll forming machine :

What are the Tool Gap Settings?

Gaps should initially be set at the material gauge with final adjustments made to achieve the desired final dimensions.


Does It Hold Dimension?

Ensure that the material within the order width and property tolerances. Check the gaps in the overbend stands for proper gauging.

Where Does the Imperfection Appear?

Inspect and check the tooling and gap settings where the imperfection occurs and in the stands upstream. Adjust to appropriate settings.


Are There Tight or Loose Areas on the Finished Panel Radii?

These imperfections typically denote improper tooling adjustment or worn tooling or bearings. Ensure that the tooling has proper gap settings. Inspect the tooling for worn areas. Inspect the line during operation for bearings with excessive movement. Occasionally, a worn bearing will make noise during operation. If bearing wears isolate and is consistently in one stand, it would be prudent to inspect the tooling in the entire line for alignment, wear and proper gap settings.


Roll Forming Systems :

Does the Tooling Run Eccentrically or Wander with Respect to Other Stands?

This is an indication of bent shafts, worn bearings, worn or misaligned tooling. If the tooling visually wanders from side to side, either the bearings are worn or the shaft locknut has come loose, or a shim has worn or fallen out. When the tooling is running in an elliptical pattern (egg shape, or up and down) the shaft itself may be bent. This will require checking the shaft for run-out with a dial indicator for the amount of movement.

This normally indicates dry material, tight clearances, or improper tooling setup. Tooling stands where material slivers and/or debris accumulate should closely monitor, as this can lead to premature wear and finish panel imperfections. Material run with insufficient lubrication (dry areas) will run with increased friction in these areas during forming. This can cause the material to scrape during the roll-forming process, especially on the panel edges. In some cases, running dry material can raise the temperature of the tooling sufficiently to reduce the die clearances from heat expansion.

Tooling that gape to less than the material being formed, or tooling that is out of alignment from stand to stand can also cause this problem. Although it is sometimes not possible to prevent material debris accumulation on some stands. tooling should gape and check for alignment frequently.

Portable roll forming machine

Does the Material Track Properly into and from the Line?

Material that has differential lubrication edge-to-edge, the material with significantly different thickness edge-to-edge or tooling that is out of adjustment can cause tracking issues.


Does the Imperfection Appear at One Stand?

If this is the case, ensure the tooling gape properly at both the imperfection stand and also at the stands prior to where the imperfection occurs.


Does the Cut-Off Operation Run Transparent to the Line?

Drag or an out-of-time cut-off operation can induce a variety of imperfections or problems. In a post-forming cut-off process, the cut-off should not alter the continuous forming of the panel. Dull cut-off dies or knives can impart sufficient drag in the cut-off operation so that the formed panel actually begins to buckle in the cut-off operation. A similar condition is possible if a flying shear is out-of-time with the speed of the forming operation. Both of these conditions should address when they first appear, as permitting them to continue will eventually cause the panel to buckle in the line prior to the cut-off.


Roll forming machine for sale

Successful roll-forming relies on a combination of factors, including material properties, tooling set-up, and roll former operation. As problems arise, it may be difficult to ascertain which factor is negatively impacting the finished panel to the point of rejection. This is why it is imperative to view the roll-forming process from a systematic point of view. With this approach, it is possible to determine the root cause of the problem and take the appropriate corrective course of action.

roll forming machine for sale

roll forming machine for sale

You can find all the information about the following :

  1. Shaft and roller design

  2. installation for roll forming machine
  3. Complete video for roll forming down roller adjustment
  4. How to fix roller position on the roll forming machine
  5. Advanced roll forming
  6. Custom Roll Forming Process
  7. Roller Die
  8. roll forming roller material
  9. How to adjust roller on the roll forming machine
  10. roll forming roller design
  11. Complete video for roll forming the base setting
  12. roll forming basics
  13. How to adjust the roll forming machine
  14. roll forming process


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